Unbound Pavement Applications of Excess Foundry System Sands: Subbase/Base Material
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1 Unbound Pavement Applications of Excess Foundry System Sands: Subbase/Base Material Tuncer B. Edil University of Wisconsin-Madison Recycled Materials Resource Center RMRC
2 Participant Job Description Which of the following describes your job? Civil Engineer or Environmental Engineer Geologist Foundry Operator Transportation Materials Engineer Construction Manager
3 Paricipant Background Private sector Public sector Planner Designer Regulator Contractor Marketing
4 UNBOUND PAVEMENT APPLICATIONS OF ESS Roadway structural systems Working Platform Subbase
5 INTRODUCTION Majority of the paved roads in the United States constructed with FLEXIBLE PAVEMENTS Asphalt Base Subbase Working Poor Subgrade Subgrade Platform Poor Subgrade
6 - Deformation during construction on soft subgrade : Impede construction equipment Complicate placement of subbase, base, and asphalt requires working platform Soft Subgrade
7 According to Tensar (1989) the soft subgrade problems can be as bad as this!!
8 Questions: How to determine thickness of working platform to limit total deflection to a certain value under construction traffic How to determine the thickness of working platform constructed with foundry sands
9 WORKING PLATFORM EQUIVALENCY SELECTION METHOD Equivalency as defined in this research requires that total deflection of the alternative material (d ta ) equal to that of breaker run (d tb ) under the same load at 1000 cycles over soft subgrade.
10 METHODOLOGY TO SELECT THICKNESS OF WORKING PLATFORM BASED ON d t A chart is developed showing: - The thickness of each working platform material to limit d t to a certain value - Equivalency between breaker run and alternative materials in terms of d t (d t-alternative materials = d t-breaker run )
11 Alternative Material Thickness, h a (m) Design Chart Relating Thicknesses 10.0 d t (mm) = 50.0 d t (mm) = 37.5 d t (mm) = 25.0 F. Slag (Tap slag) d t (mm) = B. Ash Grade 2 Gravel F. Sand with 10% bentonite (At optimum w (16%)) Note: 1.0 in = m Breaker Run Thickness, h (m) b
12 Foundry Byproduct Foundry Sand Foundry Sand Water Content Thickness in meters (inches in parenthesis) to limit total deflections to 25 mm (1 in) 21% 1.81 (71) 16% 0.32 (13) Foundry Slag Not sensitive to water content 2.55 (100)
13 8 7 d t = 50 mm [h b = 0.20 m] Note: CBR b = 80 h a / h b F. Slag d t = 25 mm [h b = 0.41 m] d t = 12 mm [h b = 0.86 m] 3 2 B. Ash 1 F. Sand Grade 2 Gravel B. Run (w=16%) Normalized CBR [CBR a / CBR b ]
14 Recap What are the requirements for a working platform over soft subgrade: (a) limit total deflections, (b) allow heavy construction traffic without getting bogged down, (c) achieve this only during construction, (d) all of the above? True or false: foundry sand bentonite content is not important True or false: foundry sand water content is important during construction
15 OBJECTIVES OF EES AS SUBBASE OF THE ROADWAY STRUCTURAL SYSTEMS STUDY To catalog pertinent engineering properties of ESS for use in roadway structural system (both as working platform and subbase) and correlate these properties to index properties To assess effect of water content and compactive effort on engineering properties.
16 SCOPE OF THE STUDY 12 clay-bonded ESS, 1 chemically bonded ESS, a base sand, and 2 reference materials (meeting WisDOT base and subbase specs) were tested in the laboratory. ESS from WI, IL, MI & IN Tests Conducted: Index Properties Compaction CBR Unconfined Compression Resilient Modulus
17 INDEX PROPERTIES D 10 : to 0.18 mm P 200 : 1.1 to 16.4% Clay Content (< 2 mm) : 0.8 to 10% Active Clay Content (methylene blue): 5.1 to 10.2% C u : 1.4 to 130 and C c : 1.1 to 69 LL : NP to 27 PI : NP to 8 (required rehydration) Particle Roundness: 0.55 to 0.69 (subrounded to subangular) G s : 2.52 to 2.73 Classify as: SC, SP, or SP-SM or A-2-4 or A-3
18 Percent Finer US Sieve No Reference Subbase Reference Base ESS 1 ESS 2 ESS 3 ESS 4 ESS 5 ESS 6 ESS 7 ESS 8 ESS 9 ESS 10 ESS 11 ESS 12 ESS 13 ESS 14 Subbase Base Particle Diameter (mm)
19 Recap What is the primary characteristic that varies between foundry sands : (a) sand roundness, (b) fines and clay content, or (c) color? True or false: Foundry sands have similar grain size distribution characteristics. True or false: Foundry sands are essentially like poorly graded sand or sand with fines. True or false: Foundry sand meet the subbase specifications exactly.
20 COMPACTION CHARACTERISTICS Some ESS behave as granular material and some cohesive. Hydration of compaction samples for 1 week is needed to reactivate the thermally deactivated clay Standard Proctor Maximum Dry Unit Weights: to kn/m 3 Optimum Moisture Contents: 9.1 to 13.8% Vibratory Table Maximum Dry Unit Weights: to kn/m 3
21 Dry Unit Weight (kn/m 3 ) ESS 5 ESS 6 ESS 8 ESS 12 ESS 13 Base S=100% G s 2.80 G s (a) Compaction Water Content (%)
22 Dry Unit Weight (kn/m 3 ) S=100% (G s 2.65) ESS 1 ESS 2 ESS 9 ESS 10 ESS 11 ESS (b) Compaction Water Content (%)
23 CBR CBR: 4 to 40 at optimum moisture content with an average 20 (20-30 considered very good for subbase) Can be estimated empirically from standard Proctor maximum density, percent fines, and roundness: CBR 32.4 dm 1.93P 264R Comparable to reference subbase Modified Proctor gives markedly higher CBR o
24 Recap True or false: Compaction curves for foundry sands appear very different than those for soils. True or false: Standard compaction procedure for soils can be used for foundry sands True or false: CBR values for all foundry sands rate as good quality for subbase purposes
25 M r (kpa) ESS 1 ESS 4 ESS ESS 7 ESS 14 Resilient Modulus: Base Reference Subbase Reference BC < 6% s b (kpa)
26 M r (kpa) Resilient Modulus: ESS 2 ESS 6 ESS 8 ESS 9 ESS 10 ESS 11 ESS 12 ESS 13 Base Reference Subbase Reference BC > 6% s b (kpa)
27 M r (kpa) Effect of Compaction Condition: BC < 6% Optimum, Std. Proctor Dry of Optimum, Std. Proctor Wet of Optimum, Std. Proctor Optimum, Mod. Proctor Low BC Sand s b (kpa)
28 M r (kpa) Effect of Compaction Condition: BC > 6% Optimum, Std. Proctor Dry of Optimum, Std. Proctor Wet of Optimum, Std. Proctor Optimum, Mod. Proctor High BC Sand s b (kpa)
29 RESILIENT MODULUS Power function best represented the data Mr K 1 s b K 2 where s b is bulk stress (s b = s d + 3 s c )
30 RESILIENT MODULUS RELATIONSHIPS K dm 111 CBR K x10 5 K 2 1 K 0.049P 3.61D 2 c 10
31 RESILIENT MODULUS Resilient modulus close to reference base material s for foundry sands with BC < 6% Resilient modulus comparable to reference subbase material s for foundry sands with BC > 6% (for optimum and dry of optimum conditions) At low s b (<200 kpa) which is typical in pavements, M r of ESS is higher than reference subbase material s
32 - Deformation after construction: (Accumulation of plastic shear strain and consolidation of the subgrade) Cracking or rutting of the asphalt under repeated traffic loading Base Subgrade
33 SN = SN 1 + SN 2 m 2 + SN 3 m 3 SN i = a i x D i, a i = f (M r-i ) SN 1, D 1 M r-1 ASPHALT a 1 SN 2, D 2 M r-2 BASE a 2, m 2 SN 3, D 3 M r-3 SUBBASE a 3, m 3 Effective Roadbed M r SUBGRADE
34 Structural Contribution as a Subbase a 3 = log M r SN 3 = a 3 x D 3 ASPHALT BASE a 3, m 3 M r-3 W. PLATFORM / SUBBASE a 3, m 3 D 3 POOR SUBGRADE
35 12.0 Structural Number of the Working Platform, SN Foundry Sand with 10% bentonite (At optimum w (16%)) Breaker Run Grade 2 Gravel Bottom Ash Thickness of the Working Platform, h (m)
36 Permanent deformation analyses using resilient moduli of foundry sands Rate of accumulation very low (e ~ 5.0x10-6 per load application) Permanent deformation very low, typically < 0.01 mm after 10 million load applications Permanent strain comparable to reference subbase, more than reference base Minimize rutting & improve performance of rigid pavements
37 RECAP True or false: Excess foundry system sands do not offer a viable and economical alternative as working platform or a subbase material. True or false: ESS are not all the same and their properties depend on their fines and active clay content as well as particle shape. True or false: Large variety of ESS have resilient modulus comparable or higher than granular subbase material.
38 FIELD VERIFICATION
39 Compaction with Padfoot Compactor
40 Maximum Deflection (mm) at 90 kn 0.0 Control (W) F/Slag F/Sand B/Ash Control (M) F/Ash Geocell GT GC GG Control (E) Oct/23/2000 May/16/2001 Oct/12/2001 May/15/2002 Oct/21/ Station
41 Elastic Modulus (MPa) (W) (M) (E) GT (b) Working Platform (Subbase) Season May, Control (W) F/Slag F/Sand B/Ash Control (M) F/Ash Geocell NonW GT GC GG Control GT (E)
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